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  Single vacuum debulk composite panel repairUSPTO Application #: 20060191624Title: Single vacuum debulk composite panel repair Abstract: A method of attaching a composite member to a structure. The method including forming a laminate of fabric impregnated with resin; applying heat at a first temperature to the impregnated laminate; applying vacuum at a first pressure to the impregnated laminate to degas the resin and form a degassed, impregnated laminate; positioning the degassed, impregnated laminate on a structure; and curing the degassed, impregnated laminate on the substrate by applying heat at a second temperature and by applying vacuum at a second pressure. (end of abstract) Agent: Pillsbury Winthrop Shaw Pittman, LLP - Mclean, VA, US Inventors: Denver Whitworth, Anthony Bergerson, Michael Marvin USPTO Applicaton #: 20060191624 - Class: 156094000 (USPTO) Related Patent Categories: Adhesive Bonding And Miscellaneous Chemical Manufacture, Methods, Surface Bonding And/or Assembly Therefor, Reclaiming, Renewing Or Repairing Articles For Reuse The Patent Description & Claims data below is from USPTO Patent Application 20060191624. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The present invention relates to the attachment of a laminate of fabric to a structure. In particular, illustrated embodiments of the present invention relate to providing fabric patches to composite structures, such as vehicles including helicopters. BACKGROUND [0002] U.S. Pat. Nos. 5,442,156 to Westerman et al.; 5,595,692 to Folsom et al.; and 4,659,624 to Yeager et al. are examples of composite structures or repairs and each is incorporated herein by reference thereto in its entirety, respectively. SUMMARY OF THE INVENTION [0003] One aspect of an embodiment of the invention is a method of attaching a composite member to a structure, comprising: forming a laminate of fabric impregnated with resin; applying heat at a first temperature to the impregnated laminate; applying vacuum at a first pressure to the impregnated laminate to degas the resin and form a degassed, impregnated laminate; positioning the degassed, impregnated laminate on a structure; and curing the degassed, impregnated laminate on the substrate by applying heat at a second temperature and by applying vacuum at a second pressure. [0004] Another aspect of an embodiment of the invention includes a method of attaching a composite patch to a structure to repair the structure, comprising: forming a laminate of fabric impregnated with resin; shaping the laminate to correspond to an area of a structure needing repair; applying heat at a first temperature to the impregnated laminate; applying vacuum at a first pressure to the impregnated laminate to degas the resin and form a degassed, impregnated laminate; positioning the degassed, impregnated laminate on the area of the structure needing repair; and curing the degassed, impregnated laminate on the area needing repair by applying heat at a second temperature and by applying vacuum at a second pressure. [0005] Another aspect of an embodiment of the invention includes a method of attaching a composite patch to a structure to repair the structure, comprising: forming a laminate of fabric impregnated with resin; shaping the laminate to correspond to an area of a structure needing repair; applying the laminate to the area of the structure needing repair; applying heat at a first temperature to the impregnated laminate; applying vacuum at a first pressure to the impregnated laminate to degas the resin and form a degassed, impregnated laminate; and curing the degassed, impregnated laminate on the area needing repair by applying heat at a second temperature and by applying vacuum at a second pressure. [0006] Aspects, features, and advantages of this invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, the principles of this invention. BRIEF DESCRIPTION OF THE DRAWINGS [0007] The accompanying drawings facilitate an understanding of the various embodiments of this invention. In such drawings: [0008] FIG. 1 illustrates a method in accordance with one embodiment of the subject invention; [0009] FIG. 2 illustrates a method in accordance with another embodiment of the subject invention; [0010] FIG. 3 illustrates a method in accordance with yet another embodiment of the subject invention; [0011] FIG. 4 illustrates an exploded view of a curing schematic in accordance with a further embodiment of the subject invention; [0012] FIG. 5 illustrates a curing schematic in accordance with an embodiment of the subject invention; and [0013] FIGS. 6-1 to 6-6 illustrate an embodiment of a repair process in accordance with an embodiment of the subject invention. DESCRIPTION OF ILLUSTRATED EMBODIMENTS [0014] FIG. 1 illustrates one embodiment of the present invention. In particular, FIG. 1 illustrates a method 10 of attaching a composite member to a structure, including: forming a laminate of fabric impregnated with resin 12; applying heat at a first temperature to the impregnated laminate 14; applying vacuum at a first pressure to the impregnated laminate to degas the resin and form a degassed, impregnated laminate 16; positioning the degassed, impregnated laminate on a structure 18; and curing the degassed, impregnated laminate on the substrate by applying heat at a second temperature and by applying vacuum at a second pressure 20. [0015] FIG. 2 illustrates another embodiment of the present invention. In particular, FIG. 2 illustrates a method 30 of attaching a composite patch to a structure to repair the structure, comprising: forming a laminate of fabric impregnated with resin 32; shaping the laminate to correspond to an area of a structure needing repair 34; applying heat at a first temperature to the impregnated laminate 36; applying vacuum at a first pressure to the impregnated laminate to degas the resin and form a degassed, impregnated laminate 38; positioning the degassed, impregnated laminate on the area of the structure needing repair 40; and curing the degassed, impregnated laminate on the area needing repair by applying heat at a second temperature and by applying vacuum at a second pressure 42. [0016] FIG. 3 illustrates a further embodiment of the present invention. In particular, FIG. 3 illustrates a method 50 of attaching a composite patch to a structure to repair the structure, comprising: forming a laminate of fabric impregnated with resin 52; shaping the laminate to correspond to an area of a structure needing repair 54; applying the laminate to the area of the structure needing repair 56; applying heat at a first temperature to the impregnated laminate 58; applying vacuum at a first pressure to the impregnated laminate to degas the resin and form a degassed, impregnated laminate 60; and curing the degassed, impregnated laminate on the area needing repair by applying heat at a second temperature and by applying vacuum at a second pressure 62. [0017] FIGS. 4 and 5 illustrate embodiments of tooling and materials that can be employed to carrying out a particular embodiment of the invention, such as, for example, the methods illustrated in FIGS. 1-3 and the particular embodiment of forming a repair patch as set forth in FIGS. 6-1 to 6-6. The assembly 70 in FIG. 4 and the assembly 72 in FIG. 5 relate to methods of repair or manufacture for a composite panel 74. In particular, the assembly 70 includes providing a vacuum device such as a vacuum bag 76 and a heating device such as a heater blanket 78 for an on-site repair wherein a debulking or degassing cycle 16, 38, 60 is performed to a repaired area 80 of composite material utilizing vacuum and applied heat prior to the curing stage 20, 42, 62, which includes the application of vacuum and heat, but at increased levels relative to the levels used during the degassing cycles 16, 38, 60. [0018] One aspect to achieving the high quality of repair in the embodiments is the use of a debulk cycle 16, 38, 60 prior to the curing phase 20, 42, 62 of the repair. This allows any volatiles generated by the resin to degas from the patch 82 before the resin and fabric are consolidated for curing. The result is a near void free, reproducible laminate 82 without clean room requirements or restrictions. [0019] The embodiments described herein employ a curing step that debulks (degasses) the resin system under a low vacuum prior to applying full compaction (vacuum) pressure. Thus, a multi-step vacuum level combined with a multi-step temperature profile is one novel aspect of this new process. Continue reading... Full patent description for Single vacuum debulk composite panel repair Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Single vacuum debulk composite panel repair patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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